Car body part

ABSTRACT

A car body part, in particular a car body part of a rail vehicle, includes an extruded part with at least one fastening portion which is suitable for fastening an item of equipment, and extends in the extrusion direction of the extruded part. The extruded part is locally weakened by mechanical reworking and the fastening portion is flexible as a result of local weakening and forms a flexible fastening portion. An assembly having the car body part and an item of equipment and a method for producing the assembly are also provided.

The invention relates to a car body part, in particular a rail vehicle car body part, in the form of an extruded part with at least one fastening portion which is suitable for fastening an item of equipment and extends in the extrusion direction of the extruded part.

In the area of fastening surfaces, in particular screwed surfaces, of car body parts and the items of equipment to be fastened on the car body parts there are always certain manufacturing-related deviations with regard to flatness and parallelism, the size of which depends on the respective manufacturing tolerances. In the case of car bodies produced from extruded sections made of aluminum, in the case of integrally molded fastening rails deviations predominantly occur in the inclination about the vehicle axis. As a result of said inclinations occurring in a manufacturing-related manner, the screwed surfaces of the fastening rails, after screw connection to an item of equipment mounted thereon, can possibly not be located in a planar manner on the screwed surfaces of the item of equipment such that a wedge-shaped gap remains. These types of wedge-shaped gaps are closed nowadays by means of wedge-shaped spacers or are compensated for by elastic connecting elements (for example screw-connected rubber bearings).

The object underlying the invention is to provide a car body part where the abovementioned wedge formation when mounting an item of equipment on the car body part does not occur at all, at least less than nowadays in the case of car bodies of the prior art.

This object is achieved according to the invention by a car body part with the features of claim 1. Advantageous developments of the car body part according to the invention are provided in the sub-claims.

Accordingly, it is provided according to the invention that the extruded part is weakened locally in a mechanical manner as a result of mechanical reworking and a fastening portion of the extruded part is flexible as a result of the local weakening and forms a flexible fastening portion.

An essential advantage of the car body part according to the invention is to be seen in that, as a result of the local weakening of the extruded part, additional flexibility of the fastening portion or fastening portions is achieved as a result of which a subsequent assembly of an item of equipment is made easier and, where applicable, a forming of a wedge between the item of equipment and the fastening portion is avoided.

It is deemed to be particularly advantageous when the extruded part includes a fastening rail (extruded at the same time) which, when viewed in the extrusion direction, is weakened locally at at least one place as a result of material removal, and the flexible fastening portion is arranged in the region, preferably spatially above, the locally weakened place (weakening place).

In addition to this or as an alternative to this, it can be provided for weakening the extruded part that the fastening rail is weakened locally or removed at at least two places (weakening places) which are located one behind another when viewed in the extrusion direction, and the flexible fastening portion is formed by a portion of the fastening rail which lies between the two places when viewed in the extrusion direction.

In cross section, the fastening rail of the extruded part can comprise a closed contour. In such a case it is deemed to be advantageous when the closed contour is opened locally to form the locally weakened places.

The fastening rail preferably comprises a square or rectangular cross section which is formed by a fastening surface, by means of two support walls which are arranged at an angle, in particular perpendicular, to the fastening surface and one carrier portion of the extruded part which holds the support walls.

In a preferred manner, one of the two support walls which is arranged at an angle, in particular perpendicular, to the fastening surface and/or the fastening surface is weakened as a result of material removal.

As an alternative to this, the fastening rail of the extruded part can comprise an open contour in cross section.

In the case of an open contour, the fastening rail of the extruded part is preferably formed by an L-section which is locally weakened and/or (completely) removed at at least two places which, when viewed in the extrusion direction, are situated one behind another and are spaced apart from one another; the flexible fastening portion, in this case, is preferably formed by a portion of the L-section which lies between the two places when viewed in the extrusion direction.

The invention relates over and above this to an arrangement having a car body part, as has been described above, as well as an item of equipment which is mounted on the car body part.

With reference to the advantages of the arrangement according to the invention, reference is made to the above statements in conjunction with the car body part according to the invention as the advantages of the car body part according to the invention correspond substantially to those of the arrangement according to the invention.

It is deemed to be advantageous when the item of equipment is mounted on the at least one flexible fastening portion which has been weakened locally in a mechanical manner as result of mechanical reworking.

In the case of a particularly preferred embodiment of the arrangement, it is provided that the item of equipment is screw-connected on the at least one flexible fastening portion and the flexible fastening portion is deformed locally as a result of the screw connection.

Over and above this, it is deemed to be advantageous when the car body part forms the roof or a roof part of a rail vehicle car body and the item of equipment is mounted on the roof or roof part.

The arrangement preferably forms a rail vehicle. In such a case, it is deemed as advantageous when the item of equipment includes or comprises one or several electro-technical or electric components of the rail vehicle, such as a converter, a transformer, an air-conditioning component or a current collector. The item of equipment can also simply provide a receptacle for operating material or equipment, for example for a converter, a transformer, an air-conditioning component, a braking resistor, a main switch, a network filter, a battery, an antenna carrier or antennae, a four-quadrant chopper, a cooling unit, a fuel container, a water container and/or another container for operating material.

The item of equipment is preferably mounted on the roof of the rail vehicle car body part.

The extruded part preferably comprises a fastening rail with a contour which is closed in cross section and is open in the region of the locally weakened place or places.

The fastening rail comprises in a particularly preferred manner a square or rectangular cross section which is formed by a fastening surface, by means of two support walls which are arranged at an angle, in particular perpendicular, to the fastening surface and one carrier portion of the extruded part which holds the support walls. The fastening surface is preferably arranged horizontally and the support walls are preferably vertical.

At least one of the two support walls which are arranged at an angle, in particular perpendicular, to the fastening surface is preferably weakened as a result of material removal or is completely removed locally. The fastening surface is preferably situated above a locally weakened support wall portion.

With reference to the fastening of the item of equipment, it is deemed to be advantageous when said item of equipment is fastened on at least two flexible fastening portions of the extruded part.

In the case of the last-mentioned embodiment, it is deemed as advantageous when in the case of each of the at least two flexible fastening portions, in each case the outside support wall—when viewed from the center of the car body—is weakened as a result of material removal.

The invention relates over and above this to a method for producing an arrangement having a car body part which is formed by an extruded section and an item of equipment.

With reference to such a method, it is provided according to the invention that the extruded part is weakened locally in a mechanical manner as a result of mechanical reworking and at least one flexible fastening portion is formed for fastening the item of equipment and the item of equipment is mounted, in particular screw-connected, along or on the flexible fastening portion.

With reference to the advantages of the method according to the invention, reference is made to the above statements in conjunction with the car body part according to the invention as the advantages of the car body part according to the invention correspond substantially to those of the method according to the invention.

In the case of an advantageous development of the method, it is provided that the extruded part is weakened locally in a mechanical manner as a result of mechanical reworking by material of the extruded part being removed, in particular as a result of milling or boring.

As a result of screw-connecting the item of equipment on the at least one flexible fastening portion, a fastening surface of the flexible fastening portion of the extruded part is pressed flatly onto a fastening surface of the item of equipment.

Over and above this, it is deemed as advantageous when, as a result of screw-connecting the item of equipment on the at least one flexible fastening portion of the extruded part, the fastening surface of the flexible fastening portion and/or the region about the fastening surface of the flexible fastening portion is deformed.

The local weakening of the extruded part is preferably effected as a result of locally opening a contour, closed in cross section, of a fastening rail of the extruded part.

In addition to this or as an alternative to it, it is deemed as advantageous when the fastening rail is weakened locally or removed at at least two places which are located one behind another when viewed in the extrusion direction and the flexible fastening portion is formed by a portion of the fastening rail which, when viewed in the extrusion direction, lies between the two places.

The invention is explained in more detail below by way of exemplary embodiments; in which, in this case, as an example:

FIG. 1 shows a cross sectional representation of an exemplary embodiment of an arrangement having a car body part and an item of equipment which is to be mounted thereon,

FIG. 2 shows in a schematic manner component tolerances which can make placing fastening surfaces of the item of equipment and of the car body part in a planar manner difficult,

FIG. 3 shows a partial representation obliquely from the side of an exemplary embodiment of a car body part and with an item of equipment mounted on a locally weakened fastening rail of the car body part, the local weakening of the fastening rail being produced as a result of holes in a support wall of the fastening rail,

FIGS. 4-7 show exemplary embodiments of different hole forms which are suitable for locally weakening the fastening rail according to FIG. 3,

FIG. 8 shows an exemplary embodiment of an arrangement having a car body part and an item of equipment mounted on the car body, a fastening rail having been laterally weakened as a result of holes as well as, over and above this, having been locally removed at places located one behind another when viewed in the extrusion direction,

FIG. 9 shows an exemplary embodiment of an arrangement having a car body part and an item of equipment mounted on a fastening rail of the car body part, a local weakening of the fastening rail being brought about as a result of holes in a support wall of the fastening rail which extend into the region of the fastening surface associated with the item of equipment,

FIG. 10 shows a cross sectional representation of the fastening rail of the arrangement according to FIG. 9,

FIG. 11 shows a top view of the fastening rail of the arrangement according to FIG. 9,

FIG. 12 shows an exemplary embodiment of a weakening of a fastening rail as a result of material removal at places that are located one behind another when viewed in the extrusion direction, the fastening portion provided for fastening the item of equipment being located between the weakened places, and

FIG. 13 shows an exemplary embodiment of a weakening of a fastening rail as a result of material removal at places that are located one behind another when viewed in the extrusion direction, the fastening portion provided for fastening the item of equipment being located between the weakened places and the fastening rail comprising an open contour or a contour which is opened locally subsequently or continuously.

For the purposes of clarity, the same references are always used in the figures for identical or comparable components.

FIG. 1 shows a car body part 10 of a rail vehicle 20 (not shown in any detail) as well as an item of equipment 30 which preferably includes a converter, a transformer, an air conditioning component or a current collector. The item of equipment 30 comprises fastening elements 40, the bottom surfaces of which in FIG. 1 forming fastening surfaces 45 for fastening the item of equipment 30 on the car body part 10.

The car body part 10 is an extruded part 11 which is provided with two extruded fastening rails 50 and 60 which are component parts of the extruded part 11 or are integrally molded in one piece on said extruded part during extrusion molding and have been extruded at the same time in one part with said extruded part and consequently extend in each case along the extrusion direction (or the longitudinal extrusion direction) of the extruded part. As an alternative to this, the car body part 10 can be formed by two or more interconnected (e.g. welded) extruded parts, one of the two extruded fastening rails being realized on one of the extruded parts and the other of the two extruded fastening rails being realized on another extruded part.

In the case of the representation according to FIG. 1, the extrusion direction of the extruded part extends perpendicular to the image plane of FIG. 1; accordingly, the two fastening rails 50 and 60 also extend perpendicular to the representation plane of FIG. 1.

Each of the two fastening rails 50 and 60 in the case of the exemplary embodiment according to FIG. 1 comprise in each case a rectangular cross section which is formed or delimited by an upper fastening surface 70, a support wall 71 which is arranged inside with reference to the vehicle center of the rail vehicle 20 and perpendicular to the fastening surface 70, a support wall 72 which is arranged outside with reference to the vehicle center of the rail vehicle 20 and perpendicular to the fastening surface 70 as well as a carrier portion 73 of the extruded part which holds the support walls. The fastening surface 70 is preferably arranged horizontally, and the two support walls 71 and 72 are preferably arranged vertically.

For mounting the item of equipment 30 on the car body part 10, the two fastening surfaces 45 of the two fastening elements 40 are fitted onto the fastening surfaces 70 of the two fastening rails 50 and 60. The fastening elements 40 are then fixed on the two fastening rails 50 and 60, for example screw-connected.

FIG. 2 shows the fastening element 40, on the right in FIG. 1, of the item of equipment as well as the fastening rail 60, on the right in FIG. 1, of the car body part in more detail. The broken lines indicate that the fastening surface 45 of the fastening element 40 and the upper fastening surface 70 of the fastening rail 60 are not always parallel to one another and can be angled in a various manner. The various inclinations of the fastening surface 45 and of the fastening surface 70 are indicated in FIG. 2 by the references +n_(G), −n_(G), +n_(RB) and −n_(RB).

Over and above this, FIG. 2 shows two force vectors F1 and F2 which are necessary in order to press the two fastening surfaces 45 and 70 onto one another. In dependence on the rigidity of the fastening surface 45 and the rigidity of the fastening surface 70, it is possible that the two fastening surfaces, during the assembly operation, that is for example during screw-connecting, cannot be aligned with respect to one another in such a manner that they actually abut in an entirely parallel manner.

In order to ensure or to simplify placing the two fastening surfaces 45 and 70 in a planar manner after mounting, in the case of the car body parts according to FIGS. 1 to 13 the fastening rails are weakened locally such that the fastening surface 70 is able to yield when the item of equipment is fastened, in particular when the item of equipment is screw-connected, and is able to be adapted to the alignment of the fastening surface 45. Exemplary embodiments of local weakening of the fastening rails of the car body part are explained in more detail below in conjunction with FIGS. 3 to 13.

FIG. 3 shows a three-dimensional representation obliquely from the side of an exemplary embodiment of a car body part 10 where the fastening rail 60 (cf. FIG. 1) is formed by an extruded part 11 and is weakened locally as a result of holes 100, as a result of which it is made flexible in the region of the fastening portions 110 which are provided for fastening the item of equipment 30 or other items of equipment. The holes 100 are arranged one behind another in the extrusion direction S of the extruded part 11 and result at said places in a flexibility or weakening of the fastening rail 60 wherever an item of equipment is subsequently to be mounted.

In the case of the exemplary embodiment according to FIG. 3, the holes 100 are arranged in the outside support wall 72 of the fastening rail 60. An arrangement of the holes 100 in the outside support wall is deemed as advantageous compared to an arrangement of the holes 100 on the inside support wall 71 in order to make it easier to adapt the upper fastening surface 70 to the fastening element 40 of the item of equipment 30. As an alternative to this or in addition to it, however, an arrangement of holes on the inner support wall would also be possible.

FIG. 3 just shows one of the two fastening rails of the extruded part 11. The statements in conjunction with the arrangement and development of the holes 100 in the case of the fastening rail 60 apply correspondingly to the fastening rail 50 according to FIG. 1. Local weakening as a result of holes, preferably on the outside support wall 72, is also performed in the case of the fastening rail 50 on the left in FIG. 1. FIGS. 4 to 7 show different embodiments of the holes 100 which can be introduced for local weakening of the fastening rails 50 and 60 according to FIG. 1 in the outer and/or inner support wall 71 or 72. The size and the contour of the holes 100 are preferably chosen in such a manner that sufficient flexibility of the fastening portions 110 (cf. FIG. 3) is achieved, but nevertheless sufficient carrying capacity for carrying the respective load is maintained.

FIG. 8 shows a second exemplary embodiment of a car body part 10 which is formed by an extruded part 11 and on which is mounted an item of equipment 30. It can be seen that the fastening rail 60 is not only weakened locally in the region of the outer support wall 72 as a result of holes 100 in order to achieve a desired flexibility in the region of the fastening portions 110, but over and above this also in the region between the fastening portions 110. Thus, it can be seen in FIG. 8 that the extruded fastening rail 70 has been completely removed at places 120, 121, and 122. The flexible fastening portions 110 of the fastening rail 60 are consequently separate from one another, as a result of which the flexibility of the fastening portions 110 is increased. Apart from this, the statements in conjunction with FIG. 3 apply correspondingly to the embodiment according to FIG. 8.

FIG. 9 shows a further exemplary embodiment of a car body part 10 on which an item of equipment 30 is mounted. It can be seen that the fastening rail 60 of the car body part 10 is not only weakened locally as a result of places 120, 121 and 122 which are located one behind another along the extrusion direction, but over and above this also as a result of holes 200 which are arranged in the outside support wall 72 of the fastening rail 60 and extend into the region of the upper fastening surface 70. It can be seen that in the region of the fastening portions 110 the upper fastening surface 70 of the fastening rail 60 is reduced as a result of the intrusion of the holes 200.

As a result of the realization of the holes 200, which extend from the outer support wall 72 into the region of the upper fastening surface 70 of the fastening rail 60, as well as over and above this as a result of the places 120, 121 and 122 which are arranged along the extrusion direction S one behind another and in which the material of the fastening rail 60 is completely removed, efficient material weakening is achieved, as a result of which a particularly high degree of flexibility is ensured in the region of the fastening portions 110.

FIG. 10 shows a more detailed cross sectional representation of the fastening rail 60 in the region of the recess 200. It can be seen that the cross section of the fastening rail 60 comprises a closed rectangular contour which has been opened locally as a result of a hole 200. In the region of the hole 200, the outer support wall 72 of the fastening rail 60 is completely removed. Over and above this, the hole 200 protrudes into the region of the upper fastening surface 70.

The inner support wall 71 of the fastening rail 60 preferably does not comprise any holes such that it is able to apply the supporting force necessary for carrying the item of equipment to be fastened on the fastening rail 60.

FIG. 10 shows over and above this a fastening hole 210 which can serve for screw-connecting the item of equipment to be fastened and not shown in FIG. 10.

FIG. 11 shows a top view of the fastening rail 60 of the car body part 10 according to FIGS. 9 and 10. It is possible to see the flexible fastening portion 110 which has been made flexible as a result of the hole 200. It can be seen that the width of the hole 200 along the extrusion direction S is greater than the fastening portion 110 which is imagined or provided for fastening an item of equipment.

As a result of the choice of the size of the hole 200 or as a result of the depth d at which the hole 200 extends into the region of the upper fastening surface 70, the flexibility of the fastening portion 110 is able to be adjusted in a targeted manner.

FIG. 12 shows a variant of a weakening of the fastening portion 110. It can be seen that, when viewed in the extrusion direction S, recesses or holes 300, which have been introduced either only in the fastening surface 70 or in addition to the fastening surface 70 also in one of the two support walls, preferably the outer support wall, have been provided upstream and downstream of the fastening portion 110. As a result of the holes 300, the fastening portion 110 becomes flexible without itself communicating directly with one of the holes.

FIG. 13 shows a further exemplary embodiment of a car body part 10 which is formed as a result of an extruded part 11 which is extruded along the extrusion direction S. It can be seen that the extruded part 11 comprises an extruded fastening rail 400 with an open section (section is open at least in portions), for example an L-section. The section of the fastening rail 400 can be produced within the framework of the extrusion process as an open section; as an alternative to this, the section of the fastening rail 400 can be produced within the framework of the extrusion process as a closed section and only opened in a local or continuous manner as a result of reworking. The fastening rail 400 is completely removed locally at the places 120, 121 and 122 which are located one behind another along the extrusion direction S such that the upper fastening surface 410 is flexible or yielding and can be easily adapted to the alignment of a fastening element 40 of an item of equipment 30 which is to be mounted on the fastening rail 400. The fastening portions, which are formed by the upper fastening surface of the fastening rail 400, are marked in FIG. 13 by way of the reference 420. A fastening element of an item of equipment 30 is mounted on the rear fastening portion 420 in FIG. 13.

The above exemplary embodiments can comprise one or several of the following features depending on the development:

-   -   the carcass-side fastening rail of the car body part is machined         such that the outside vertical web (support wall 72 in FIGS. 1         and 3) of the fastening rail is omitted completely or at least         in part in the region of the fastening portion or screwed         surface.     -   The inner vertical web of the fastening rail directly transmits         the vertical weight because it communicates with the horizontal         bearing surface and is covered at least in part by said bearing         surface.     -   The horizontal bearing surface serves as a screwed surface and         transmits longitudinal and transverse forces.     -   As a result of weakening the fastening rail, the fastening rail         becomes more flexible for torsion about the longitudinal axis of         the fastening rail and about the axis of the extruding direction         of the extruded section without losing strength at the relevant         carrying places.     -   Where the design of the rigidity of the item of equipment, the         fastening of the item of equipment and development of the         fastening rail is coordinated, the fastening portions or the         screwed surfaces can be moved to the desired abutment under the         preload force.

Although the invention has been illustrated and described in more detail by the preferred exemplary embodiments, the invention is not restricted by the disclosed examples and other variations can be derived therefrom by the expert without departing from the scope of protection of the invention. 

1-15. (canceled)
 16. A car body part or rail vehicle car body part, comprising: an extruded part having at least one fastening portion being suitable for fastening an item of equipment and extending in an extrusion direction of said extruded part; said extruded part being mechanically reworked to provide a local weakening; and said at least one fastening portion being flexible due to said local weakening, forming at least one flexible fastening portion.
 17. The car body part according to claim 16, wherein: said extruded part includes a fastening having material removed to form at least one locally weakened location along said extrusion direction; and said at least one flexible fastening portion is disposed in the vicinity of said at least one locally weakened location.
 18. The car body part according to claim 17, wherein said at least one flexible fastening portion is disposed above said at least one locally weakened location.
 19. The car body part according to claim 16, wherein: said extruded part includes a fastening rail being weakened locally or removed at least at two locations disposed one behind another in said extrusion direction; and said at least one flexible fastening portion is formed by a portion of said fastening rail lying between said two locations in said extrusion direction.
 20. The car body part according to claim 17, wherein said fastening rail of said extruded part has a cross section with a closed contour being open in the vicinity of said at least one locally weakened location.
 21. The car body part according to claim 19, wherein said fastening rail of said extruded part has a cross section with a closed contour being open in the vicinity of said locally weakened locations.
 22. The car body part according to claim 17, wherein said fastening rail of said extruded part has a cross section with an open contour.
 23. The car body part according to claim 19, wherein said fastening rail of said extruded part has a cross section with an open contour.
 24. An assembly, comprising: a car body part according to claim 16; and an item of equipment mounted on said at least one mechanically reworked and locally mechanically weakened flexible fastening portion of said car body part.
 25. The assembly according to claim 24, wherein said item of equipment is screw-connected on said at least one flexible fastening portion and said at least one flexible fastening portion is deformed locally as a result of said screw connection.
 26. The assembly according to claim 24, wherein: said car body part forms a roof or a roof part of a rail vehicle car body; and said item of equipment is mounted on said roof or roof part.
 27. The assembly according to claim 26, wherein: the assembly forms a rail vehicle; said item of equipment includes a converter, a transformer, an air-conditioning component or a current collector or is formed by a component; and said item of equipment is mounted on said roof of said rail vehicle car body part.
 28. A method for producing an assembly having a car body part formed by an extruded part and an item of equipment, the method comprising the following steps: mechanically weakening the extruded part locally by mechanical reworking and forming at least one flexible fastening portion for fastening the item of equipment; and mounting the item of equipment on or at the at least one flexible fastening portion.
 29. The method according to claim 28, which further comprises carrying out the mounting step by screw-connecting the item of equipment on or at the at least one flexible fastening portion.
 30. The method according to claim 28, which further comprises removing material of the extruded part to carry out the step of weakening the extruded part locally by mechanical reworking.
 31. The method according to claim 30, which further comprises carrying out the step of removing the material of the extruded part by milling or boring.
 32. The method according to claim 29, which further comprises pressing a fastening surface of the item of equipment flatly onto a fastening surface of the at least one flexible fastening portion of the extruded part as a result of the screw-connecting of the item of equipment at the at least one flexible fastening portion.
 33. The method according to claim 32, which further comprises deforming a region about the fastening surface of the at least one flexible fastening portion as a result of the screw-connecting of the item of equipment on the at least one flexible fastening portion of the extruded part.
 34. The method according to claim 28, which further comprises effecting the local weakening of the extruded part by locally opening a contour having a closed cross section of a fastening rail of the extruded part.
 35. The method according to claim 28, which further comprises: locally weakening or removing a fastening rail of the extruded part at least at two locations disposed one behind another in an extrusion direction; and forming the at least one flexible fastening portion by a portion of the fastening rail disposed between the two locations in the extrusion direction. 